Tray



June 8, 19465 ATTORN EY;-

Jupe 8, 1965 1 ENTOR. GEORGE SKOWRONSKI BYJMWQM AT T0 R N EY I June 8, 1965 G. v. sKowR EoRGE SnowRoNsm C 8% ATTORNEY United States Patent O 3,187, 979 TRAY George V. Skowronski, Neenah, Wis., assignor to American Can Company, New York, N.Y., a corporation of New Jersey Filed Jan. 17, 1963, Ser. No. 252,090 4 Claims. (Cl. 229-28) This invention relates to multi-compartment trays. More specifically, the invention relates to tapered trays having a plurality of receptacle portions, particularly suitable for packaging bakery products, which can be readily set up by automatic machinery and shipped in stacked and nest form.

Divided or compartmented trays customarily have vertical sides and a unitary bottom panel coextensive with the area dened by the outer sides of the tray. `Such a construction makes it impossible to ship erected divided trays in a stacked or nested form to save space. Even if the sides of the tray are tapered, the full bottom prevents nesting of the carton. Therefore the trays are usually shipped in the form of collapsed blanks to the product packager, who erects or sets up the trays. The setting up of the trays requires either a substantial labor cost or a capital expenditure for tray erection equipment.

Further, the formation of a divided tray from a unitary blank or several blanks is usually quite involved, and the resulting tray often lacks rigidity. When used in the baking industry, it is extremely desirable that the tray be suitable for baking of the product therein. The construction should be such that dough can be deposited in individual pockets or compartments, which are of sufficient rigidity to maintain their shape during expansion of the dough while baking. From the standpoint of ease of erection, rigidity of construction and lower investment cost to the packager, it is desirable to provide a tapered tray construction which has increased rigidity due to separate, reinforced pockets or compartments, and which allows nesting of the tray in a stack of other substantially identical trays. j

It is therefore an object of the present invention to provide a divided tray, having tapered compartments or pockets, which is suitable for stacking in a nested condition.

A further object of the present invention is to provide a divided tray suitable for baking wherein the compartments or pockets retain their original shape throughout the baking of products located therein,

Yet another object of the present invention is to provide a divided tray wherein no one compartment has a side wall or bottom common to another compartment and shifting of product from one compartment to another is avoided.

Still another object of the present invention is to provide a divided tray in which the compartments are substantially siftproof to prevent leakage of product located therein.

Another object of the present invention is to provide a tray which readily can be set up on automatic machinery.

Further details, advantages and objects will be apparent from the following specification and appended drawings wherein:

FIGURE 1 is a plan view of a female tray forming blank,

FIGURE 2 is a plan view of a male insert blank,

FIGURE 3 is a fragmentary perspective view of the blank of FIGURE 1 folded for reception of the male insert,

FIGURE 4 is a fragmentary perspective of the blank of FIGURE 2 folded for insertion in the openings of the female blank,

FIGURE 5 is a fragmentary perspective View of the ICC tray according to the present invention with the male blank inserted in the female blank to form compartments or pockets,

FIGURE 6 is a perspective view of the completed tray,

FIGURE 7 is a fragmentary perspective View of the bottom of the completed tray,

FIGURE 8 is a fragmentary perspective view of the completed tray according to the present invention employing a modified pocket forming construction, and

FIGURE 9 is a, fragmentary perspective view of the bottom of the modified pocket construction.

Referring to FIGURES l and 2, the tray is formed from two blanks, A and B. Blank A, shown in FIGURE l, is preferably made of paperboard and constitutes the female tray forming portion of the tray. Blank A is divided by score lines 10-12, 14 and 15, and cut lines 13, 16, 17 and 18 into hingedly connected walls, panels and flaps including side walls 30 and 32, center panel 31, glue tabs 33, side panels 34, and end flaps 35. Blank B, shown in FIGURE 2, also is preferably made of paperboard having a heat-scalable coating on the bottom side and constitutes the male pocket forming portion of the tray. Blank B is divided by score lines Sil-54 and cut lines 55 into hingedly connected panels and flaps including edge panels 6i), connecting panels 61 and 62, bottom panels 63, end panels 64 and side flaps 65. As is obvious from a comparison of FIGURES l and 2, blank B is larger in its longitudinal dimension than blank A. Therefore, in order for the edge panels 60 of blank B to coincide with the side walls 30 of blank A in the completed tray shown in FIGURE 6, it is necessary for blank B to be reduced in size by an accordian type of folding. The actual folding will be described hereinafter with reference to the insertion of blank B into blank A.

The blanks A and B of FIGURES 1 and 2, respectively, are formed into the configurations shown in FIGURES 3 and 4, prior to combining them to form the divided tray. In blank A side panels 34 and attached end flaps 35 are folded downwardly about score lines 15 to the position shown in FIGURE 3. End flaps 35 are positioned at an angle to side panels 34 by folding the end flaps about score lines 14. The initial folding and the subsequent holding in position of the panels and flaps can be readily accomplished by seating the blank over a female die at least coextensive in area with the outer perimeter of the blank. The openings in the balnk correspond to cavities in the die. A male die having projections of substantially the same configuration as the cavities is then lowered on the blank. The projections force the panels 34 and aps 35 down against the sides of the cavities, which sides have Vacuum cups located therein. As the sides and flaps of the blanks contact the sides of the cavities, a vacuum is drawn and the sides and flaps held in place.

Blank B is .formed into the configuration shown in FIG- URE 4 by depressing .bottom panels 63, causing connect- .ing panels 61 and 62 to 4be drawn closer together, and folding side flaps 65 upwardly. In FIGURE 4 edge panels 60 and 4connecting panels 61 and 62 lie in the same plane with .bottom panels 63 in a separate, parallel plane. End panels `64 are .hinged to connecting panels `611 Iand 62 along score lines 51 and 52 and to bottom panels 63 along score lines 53, and are positioned at an angle to the bottom panels as -are side ilaps 65 hinged along score lines 54. The folding of blank B can be performed either independently of insertion into .blank A or else in conjunction or simultaneously with .the insertion of elements 63-65 in the openings in blank A. When performed as a simultaneous process, Iblank B having the thermoplastic, heatscalable Icoating on the underside is placed in superposed relationship on blank A located on the female die. 'Ihe free edge of leading edge panel 6@ parallel to score line 50 is aligned with the free edge of leading side -wall 30 of blank A. The leading row of pocket dormi-ng elements 163-65 `are then forced down into the cavities in the female mold by heated plungers to form completed pockets or compartments. Sufficient heat and pressure is applied by the 'female cavities .and the coacting plungers to activate the adhesive, thereby sealing the elements of each of the formed .blanks together. A second set of pocket forming plungers, either attached to the first set or independent thereof, forms the second row of completed pockets. The process is .continued until `all of .the pockets in the tray :are completed. As each set `of plungers depresses a row of pocket forming elements, blank B is reduced in its lon- `gitudinal dimension by the accordian type of folding ac-V tion mentioned previously. After depression of the last row ofv pocket `forming elements, the free edge of trailing edge panel 6l) coincides with the free edge of trailing side wall 30. Portions of the plungers extend beyond the con- 4fines of the cavities to apply heat and pressure to the edge panels 60 and connecting panels 61 and 612 of blank B to v adhere .them to the underlying side walls 3d and center panel `31 of blank A. FIGURE 5 shows the tray with the pockets or compartments formed and the `flange elements of the blanks a-dhered to each other.

Instead of employing a thermoplastic heat-sealable coating on .blank B for adhering the two blanks together,v an adhesive may be applied to blank A in the areas indicated by the stippling on FIGURE l. The `adhesive is applied to portions of side walls 34B, center panel 3l, side panels 34 and end flaps 35 by straight line applicators. After :application of the adhesive, blank A is positioned over the female die. Blank B is then placed in superposed relationship on blank A with Ithe leading free edges of the blanks coinciding. The first set lof plungers then depresses the .pocket for-ming elements of both blanks simultaneously, forming completed pockets in one step. Any smearing of the adhesive on blank A is immaterial since it is .covered by the elements of blank B. rlhe tray is completed by forming the remainder of the completed pockets with additional sets of plungers. The appearance of the tray produced in this manner is the same `as shown in FIGURE 5.

The tray is completed by applying adhesive at the underside of glue t-abs 33, folding the glue tabs 33 inwardly :about score lines 12, infolding side walls 3@ and adhered edge panels 60 about score lines l@ and 5t), respectively7 to a `substantially upright position, and then infold-side walls 32 about `score lines lll and adhering the end portions thereof to the adhesive bearing surfaces of glue flaps 33. In the completed tray the edges of the side walls 39 dened by score lines 12 coincide with the end edges of side wall-s 32. T he opstanding side walls, which give greater rigidity to the tray, are inclined at an angle to the center panel to enable a number of the `completed trays .shown in FIGURE 6 `to be stack-ed in a nested condition. It is obvious that if desired the side walls 32 and glue aps 33 can be omitted and the tray produced without upstanding side ywall portions.

Each individual pocket or compartment has several lareas giving greater rigidity. Side flaps 65 not only provide a double thickness where adhered to side panels 34, but the end edges of the side flaps abut the end panels 64 maintaining the shape o-f the pockets. Referring to FIG- URE 7 which shows the bottom of the completed tray, the end flaps v35 -overlap the end panels 64 .again providing a double wal thickness. The above noted features prevent shifting of the pocket elements and assure substantial siftd proofness of each pocket. If i-t is desired to completely siftproof the pockets, they can be sprayed or coated to seal the corners thereof.

Referring next to FIGURE 8, there is .shown a modification of .the tray according to the present invention. The side tlaps 65 instead of being superposed on the inner surface of side panels `34 are adhered to the outer surface of the side panels. FIGURE 8 shows the bottom of the modified tray construction. Changing the location of the side flaps `65 incr-eases the rigidity of the pocket but also increases the `complexity of the erection process.

If it is desired to utilize the completed tray for the baking of the contents packaged therein, it `is necessary to ernploy a lining material, such as foil, to prevent burning or scorching of the contents. Both of the blanks A and B employ a layer of foil on the upper surfaces thereof for baking purposes. The use of the board foil combination eliminates the burning or scorching encountered when board alone is used and the uneven baking when foil alone i-s employed.

y The present invention provides a rigid tapered tray which can be stacked for shipment in a nested condition. Employment of reinforced pockets separated from each other prevents product shifting and provides essential siftproofness for the contents. The tray can readily be rendered completely siftproof if desired and by the employment of a proper lining material be used for baking of the contents packaged therein. Although exemplified with twelve pockets it is understood that the size and shape of the tray may be varied as desired without departing from the sco-pe of this invention.

I claim:

l. A multi-compartment, nestable tray comprising an upper planar panel connecting a plurality of separate tapered cup-like receptacle portions extending downwardly 4from said upper panel, said upper planar panel spacing each of said receptacle por-tions from the other receptacle portions, each of said receptacle portions comprising a bottom panel and a pair of opposed end panels hingedly connected to said upper panel and to said bottom panel, said end panels being incl-ined downwardly and inwardlytoward each other; a pair of opposed side flaps .hingedly connected t-o the remaining edges of said bottom panel, said side aps being inclined downwardly and inwardly toward each other; a pair of opposed side panels transverse to said end panels and hingedly depending from said upper panel, said lside panels being inclined downwardly and inwardly toward each other; said side panels and side aps being adhered together intermediate the .bottom panel and the upper panel.

2. The tray of claim 1 having end flaps hingedly connected to said end edges of said `side panels and adhered to said end panels.

3. The tray of claim l wherein the end edges of said side flaps are in frictional contact with said end panels.

4. The tray of claim 2 I,wherein the end edges of said side tiaps are in frictional contact with said end panels.

References Cited by the Examiner UNITED STATES PATENTS 10/49 Holes 229-28 4/52 Inman 229-28 

1. A MULTI-COMPARTMENT, NESTABLE TRAY COMPRISING AN UPPER PLANAR PANEL CONNECTING A PLURALITY OF SEPARATE TAPERED CUP-LIKE RECEPTACLE PORTIONS EXTENDING DOWNWARDLY FROM SAID UPPER PANEL, SAID UPPER PLANAR PANEL SPACING EACH OF SAID RECEPTACLE PORTIONS FORM THE OTHER RECEPTACLE PORTIONS, EACH OF SAID RECEPTACLE PORTIONS COMPRISING A BOTTOM PANEL AND A PAIR OF OPPOSED END PANELS HINGEDLY CONNECTED TO SAID UPPER PANEL AND TO SAID BOTTOM PANEL, SAID END PANELS BEING INCLINED DOWNWARDLY AND INWARDLY TOWARD EACH OTHER; A PAIR OF OPPOSED SIDE FLAPS HINGEDLY CONNECTED TO THE REMAINING EDGES OF SAID BOTTOM PANEL, SAID SIDE FLAPS BEING INCLINED DOWNWARDLY AND INWARDLY TOWARD EACH OTHER; A PAIR OF OPPOSED SIDE PANELS TRANSVERSE TO SAID END PANELS HINGEDLY DEPENDING FROM SAID UPPER PANEL, SAID SIDE PANELS BEING INCLINED DOWNWARDLY AND INWARDLY TOWARD EACH OTHER; SAID SIDE PANELS AND SIDE FLAPS BEING ADHERED TOGETHER INTERMEDIATE THE BOTTOM PANEL AND THE UPPER PANEL. 